KR101870489B1 - Resin composition for fixing, rotor, automobile, and method for manufacturing rotor - Google Patents

Abstract

A solid fixing resin composition excellent in charging characteristics and a rotor using the same. A rotor core (110) having a laminated body in which a plurality of plate members are laminated, a rotor core (110) fixed to the rotating shaft and having a plurality of holes (150) arranged along the periphery of the rotating shaft, A magnet 120 inserted into the hole portion 150 and a fixing member 130 formed by hardening the fixing resin composition filled in the hole portion 150 and the hollow portion of the magnet 120, (A), a curing agent (B) and an inorganic filler (C), wherein the epoxy resin has an ICI viscosity at 150 ° C of 3 poise or less.

Description

TECHNICAL FIELD [0001] The present invention relates to a resin composition for fixing, a rotor, an automobile, and a method of manufacturing a rotor,

The present invention relates to a fixing resin composition for use in a rotor, a rotor, an automobile, and a method of manufacturing a rotor.

The present application claims priority based on Japanese Patent Application No. 2011-260440 filed on November 29, 2011, the contents of which are incorporated herein by reference.

Recently, in the technical field of the rotor, a technique of inserting a permanent magnet into a hole formed in a rotor core and filling a liquid resin between the hole and the permanent magnet has been used to fix the permanent magnet to the rotor core. In this technical field, urethane resin, epoxy resin or the like is generally used as a liquid resin. Such a technique is described in, for example, Patent Document 1. [

Patent Document 2 discloses an epoxy resin for motor sealing used for sealing a motor and a molded article obtained by curing the epoxy resin. In this molded article, it is described that work environment, productivity, heat resistance, thermal conductivity, solvent resistance, high humidity resistance and low linear expansion coefficient are obtained. For this reason, it is considered that the molded article described in Patent Document 2 is used for a housing of a motor.

The rotor disclosed in Patent Document 3 has a structure in which a second hole portion communicating with the first hole portion and along the rotational direction of the rotor is formed on the side surface of the first hole portion for accommodating the permanent magnet. By filling the second hole portion with the resin or by arranging the spring, the stress that the permanent magnet receives from the side wall of the first hole portion in the rotation direction of the rotor is relaxed. Thus, it is described that the permanent magnet can be prevented from cracking.

In addition, as a method of filling liquid resin between the hole portion of the rotor core and the magnet, there are two methods, that is, a first introduction method and a coating method. The first-in-first-out method has the following steps. First, the liquid resin is filled in the hole portion of the rotor core by a dispenser. Thereafter, the magnet is inserted into the hole filled with the liquid resin. The first-in first-out method is described in Patent Documents 4 and 5. On the other hand, the coating method has the following steps. First, the liquid resin is applied to the magnet with a brush. Insert the magnet coated with the liquid resin into the hole of the rotor core. The application method is described in Patent Document 6.

Japanese Patent Application Laid-Open No. 2007-236020 Japanese Laid-Open Patent Publication No. 2009-13213 Japanese Patent Application Laid-Open No. 2002-359942 Japanese Patent Application Laid-Open No. 2005-304247 Japanese Laid-Open Patent Publication No. 11-98735 Japanese Patent Application Laid-Open No. 2003-199303

It is difficult to apply the technique of filling the liquid resin to the hole portion of the rotor core and the injection method of injecting the resin into the gap of the magnet previously inserted into the hole portion.

The epoxy resin described in Patent Document 2 is intended to cover the entire motor. For this reason, it is difficult to use the resin described in Patent Document 2 for the purpose of fixing the permanent magnets.

As a result of the investigation by the inventors of the present invention, it has been found that the resin can be filled in the gap of the magnet inserted beforehand in the hole portion of the rotor core and the hole portion by employing the insert molding.

However, when the gap between the hole portion of the rotor core and the magnet is narrow, the molten resin may not be filled in the gap. Therefore, the inventors of the present invention have thought that there is room for improvement in the melt viscosity of the solid resin in order to improve the filling property into the gap.

According to the present invention, there is provided a rotor comprising: a rotor core having a laminate in which a plurality of plate members are laminated, a plurality of holes formed in the laminate so as to be fixed to a rotating shaft and disposed along a periphery of the rotating shaft; And a fixing member formed by curing the fixing resin composition filled in the hollow portion of the magnet and the hole, the magnet being inserted into the hole portion, and the fixing resin constituting the fixing member constituting the rotor There is provided a fixing resin composition containing a thermosetting resin (A) containing an epoxy resin, a curing agent (B) and an inorganic filler (C), wherein the epoxy resin has an ICI viscosity of 3 poise or less at 150 캜 .

According to the present invention, there is provided a solid fixing resin composition having excellent charging characteristics and a rotor using the same.

The foregoing and other objects, features and advantages of the present invention will become more apparent from the following description of a preferred embodiment and accompanying drawings.
BRIEF DESCRIPTION OF DRAWINGS FIG. 1 is a top view schematically showing a rotor according to an embodiment of the present invention. FIG.
Fig. 2 is a top view schematically showing a mold for insert molding according to an embodiment of the present invention. Fig.
3 is an enlarged view schematically showing a part of the rotor in the embodiment of the present invention.
4 is a cross-sectional view schematically showing a part of a rotor according to an embodiment of the present invention.
6 is a cross-sectional view showing a modified example of the rotor in the embodiment of the present invention.
7 is a top view schematically showing a rotor in a modified example.
8 is a top view schematically showing a rotor in a modified example.
Fig. 9 is a top view schematically showing a rotor in a modified example. Fig.

DESCRIPTION OF THE PREFERRED EMBODIMENTS Hereinafter, embodiments of the present invention will be described with reference to the drawings. In all the drawings, the same constituent elements are denoted by the same reference numerals, and a description thereof will be omitted.

1 is a top view of a rotor according to an embodiment of the present invention. 3 is a partially enlarged view of the rotor in the embodiment of the present invention. 4 is a partial cross-sectional view of a rotor according to an embodiment of the present invention. The rotor 100 of the present embodiment includes a rotor core 110, a magnet 120, and a fixing member 130. The rotor core 110 has a laminate in which a plurality of plate members (electromagnetic steel plates) are laminated. The rotor core 110 is fixed to the rotating shaft (shaft 170). In the rotor core 110, a plurality of holes 150 arranged along the periphery of the rotating shaft are formed in the laminate. The magnet 120 is inserted into the hole portion 150. The fixing member 130 is formed by hardening the fixing resin composition filled in the hole portion 150 and the hollow portion of the magnet 120.

The rotor core 110 is constituted by laminating a plurality of electromagnetic steel plates (steel plates 112) as a magnetic substance on a thin plate. The rotor core 110 is formed with a through hole for inserting the shaft 170 therein. The rotor core 110 can be formed, for example, in a cylindrical shape. The shape of the rotor core 110 as viewed from the upper surface thereof is not particularly limited, but may be, for example, circular, polygonal, or the like. The plurality of electromagnetic steel plates are coupled to each other by caulking parts 160. The electromagnetic steel sheet is composed of, for example, iron or an iron alloy. An end plate 114 is formed at an axial end portion of the rotor core 110. The end plate 114 may be provided with a groove portion 116 for avoiding interference between the caulking portion 160 and the opening portion of the charging portion 140.

The plurality of holes 150 (or hole groups constituted by a plurality of holes) are disposed in the rotor core 110 such that they are point-symmetrical about the axial center of the rotating shaft. The number of the hole portions 150 is not particularly limited, but may be, for example, 2 ⁿ or 3 ⁿ (n is a natural number, for example, 2 to 5). A magnet 120 is inserted into each of the holes 150. The hole portion 150 may be configured to follow the shape of the magnet 120 and may have a margin (gap portion) around the corner portion of the magnet 120, for example.

The layout of the holes 150 is not limited to the embodiment shown in Fig. 1, and various layouts shown in Figs. 7 to 9 may be employed, for example. A group of holes, which is one set of two or three holes 150, may be arranged along the periphery of the rotating shaft. As shown in Fig. 1, each of the hole groups may be constituted by two hole portions which are separated from each other and arranged in a V-shape. 9, the hole group may be constituted by the holes 154a and 154b and the hole 156 formed between these holes 154a and 154b. Further, as shown in Fig. 8, the holes arranged in the V-shape may communicate with each other to constitute one hole portion 152. Fig. 7, the plurality of holes 150 may be arranged so that the holes 150 are spaced apart from each other at positions orthogonal to the direction in which the shaft is loosened.

The magnet 120 may be fixed within the hole 150. 3 and 4, the magnet 120 may be fixed to the side wall 151 located on the outer peripheral side of the rotor core 110 among the side walls of the hole portion 150. [ That is, the side wall 121 of the magnet 120 may be in contact with the side wall 151 of the hole portion 150. In other words, the fixing resin composition relating to the present invention may be filled in the side wall of the hole portion 150 other than the side wall 151 and the interspace (charging portion 140) of the magnet 120. The fixing resin composition is cured to form the fixing member 130. The fixing member 130 may be formed between each corner of the hole portion 150 and the magnet 120. Here, as the magnet 120, for example, a permanent magnet such as a neodymium magnet can be used.

3 and 4, the side wall 153 indicates that the sidewall of the hole portion 150 is located on the inner peripheral side of the rotor core 110. As shown in Fig. The side wall 123 refers to the side wall 153 of the hole 150 in the side wall of the magnet 120.

3 or 4, in the rotor core 110, the gap width D1 of the gap between the hole portion 150 and the magnet 120 in the radial direction is smaller than the gap width D1 between the hole portion 150 and the magnet 120, The distance from the side wall 153 of the magnet 120 to the side wall 123 of the magnet 120 is defined. When the gap is present, it is preferable that the interval width D1 is 20 占 퐉 or more and 500 占 퐉 or less. More preferably not less than 50 mu m and not more than 300 mu m. By setting the gap width D1 within the above range, a good mechanical strength can be imparted to the rotor.

As a result of the investigation by the inventors, it has been found that the resin is liable to be unfilled in the area of the threat.

On the other hand, by using the resin composition for fixing according to the present invention, which has excellent filling characteristics, it is possible to suppress the occurrence of unfilled resin in the compromised region. Thus, the rigidity of the rotor 100 can be improved because the fixing member 130 is well filled in the gap between the hole portion 150 and the magnet 120. Therefore, the noise generated from the rotor at the time of rotation can be reduced.

As shown in Fig. 6, the end plates 118a and 118b may be fixed to the shaft 170 by welding or the like. The fixing member 130 may not be formed on the sidewall of the outer peripheral side of the magnet 120 in the hole portion 150. However, as shown in Fig. 6, the outer peripheral side and the outer peripheral side of the magnet 120 The fixing member 130 may be formed on both side walls of the inner peripheral side.

Each component of the fixing resin composition constituting the rotor 100 of the present invention will be described below.

The fixing resin composition is used for forming a rotor and forming a vehicle having a rotor. That is, the fixing resin composition is used for fixing a magnet disposed in a hole formed in a rotor core composed of an electromagnetic steel sheet.

(Fixing resin composition)

The solid fixing resin composition according to the present invention contains a thermosetting resin (A) containing an epoxy resin, a curing agent (B) and an inorganic filler (C). The fixing resin composition is specified by the ICI viscosity of the epoxy resin at 150 占 폚 being 3 poise or less. The resin composition for fixation had a slit when injecting the resin composition for fixation into a flow path having a cross-sectional shape of 3 mm in width and 80 탆 in thickness under conditions of a mold temperature of 175 캜, a molding pressure of 6.9 MPa, The flow length is 75 mm or more. The slit flow length at this time is preferably 75 mm or more and 300 mm or less, more preferably 80 mm or more and 300 mm or less.

[Thermosetting resin (A)]

First, the thermosetting resin (A) will be described.

The thermosetting resin (A) is not particularly limited, but an epoxy resin (A1), an oxetane resin, a (meth) acrylate resin, an unsaturated polyester resin, a diallyl phthalate resin, a maleimide resin and the like are used. Among them, an epoxy resin (A1) having excellent curability and storage stability, heat resistance of a cured product, moisture resistance, and chemical resistance is preferably used.

The thermosetting resin (A) according to the present invention contains an epoxy resin (A1). Examples of the epoxy resin (A1) include those having two or more epoxy groups in one molecule.

The molecular weight and structure of the epoxy resin are not particularly limited, but it is preferable that the viscosity of the fixing resin composition is lowered. The upper limit of the ICI viscosity at 150 캜 of the epoxy resin (A1) is 3 poise or less, preferably 1.5 poise or less. The lower limit is not particularly limited, but is preferably 0 poise or more, and more preferably 0.01 poise or more. This makes it possible to improve the filling property of the resin composition for fixing, and even when the gap between the hole portion and the magnet is narrow, it is possible to secure a sufficient adhesion area between the steel plate and the magnet, and consequently to provide a high mechanical strength.

Examples of the epoxy resin (A1) include biphenyl type epoxy resins, phenol aralkyl type epoxy resins having a biphenylene skeleton, phenol aralkyl type epoxy resins having a phenylene skeleton, naphthol ars having a phenylene skeleton Phenol novolac epoxy resins, orthocresol novolac epoxy resins, bisphenol A epoxy resins, bisphenol F epoxy resins, phenol novolac epoxy resins, phenol novolac epoxy resins, phenol novolac epoxy resins, A bisphenol epoxy resin, a bisphenol epoxy resin, a dicyclopentadiene epoxy resin, a dihydroanthracene diol epoxy resin, and a triphenylmethane epoxy resin, such as bisphenol S type epoxy resin and tetramethyl bisphenol type epoxy resin, .

Among them, the epoxy resin (A1) is preferably a phenol aralkyl type epoxy resin having a phenylene skeleton, a phenol aralkyl type having a biphenylene skeleton An epoxy resin, and a triphenylmethane type epoxy resin. These may be used alone or in combination of two or more.

The content of the thermosetting resin (A) according to the present invention is not particularly limited with respect to the total value of 100% by mass of the fixing resin composition, but is preferably 5% by mass or more and 40% by mass or less, more preferably 7% % Or less.

In the preferred embodiment containing the epoxy resin (A1) according to the present invention, the lower limit of the content of the epoxy resin is not particularly limited, but is preferably 70% by mass or more and 100% by mass or less based on 100% by mass of the thermosetting resin (A) , And more preferably 80 mass% or more and 100 mass% or less.

[Curing agent (B)]

Next, the curing agent (B) will be described. The curing agent (B) is used for three-dimensionally crosslinking the epoxy resin (A1) contained in the thermosetting resin (A). The curing agent (B) is not particularly limited, but it is preferable that the viscosity of the fixing resin composition is lowered. The upper limit of the ICI viscosity at 150 캜 is preferably 2 poise or less, more preferably 1.8 poise or less, and further preferably 1.7 poise or less, for example, in the curing agent (B). The lower limit is not particularly limited, but is preferably 0 poise or more, and more preferably 0.01 poise or more.

The curing agent (B) may be, for example, a novolak type phenol resin, a phenol aralkyl resin having a phenylene skeleton, a phenol aralkyl resin having a biphenylene skeleton, a naphthol aralkyl resin having a phenylene skeleton, A phenol resin mainly comprising a reaction product of benzaldehyde, formaldehyde and phenol, and a phenol resin such as a copolymer of a triphenylmethane type phenol compound and a novolac type phenol compound. These may be used alone or in combination of two or more. Such a phenol resin-based curing agent improves balance among flame retardancy, moisture resistance, electrical properties, curability, storage stability and the like. Particularly, from the viewpoint of curability, for example, the hydroxyl group equivalent of the phenolic resin-based curing agent can be 90 g / eq or more and 250 g / eq or less.

Examples of the curing agent that can be used in combination include a middle part type curing agent, a catalyst type curing agent, and a condensation type curing agent.

Examples of the middle part type curing agent include aliphatic polyamines such as diethylenetriamine (DETA), triethylenetetramine (TETA) and meta xylene diamine (MXDA), diaminodiphenylmethane (DDM), m- Polyamine compounds containing dicyandiamide (DICY), organic acid dihydrazide and the like, in addition to aromatic polyamines such as diamine (MPDA) and diaminodiphenylsulfone (DDS); (TMA), anhydrous pyromellitic acid (PMDA), benzophenone tetracarboxylic acid (BTDA), and the like, such as hexahydrophthalic anhydride (HHPA) and methyltetrahydrophthalic anhydride (MTHPA) An acid anhydride containing an aromatic acid anhydride and the like; Polyphenol compounds such as novolak type phenol resin and phenol polymer; Polymercaptan compounds such as polysulfide, thioester, and thioether; Isocyanate compounds such as isocyanate prepolymer and blocked isocyanate; And organic acids such as carboxylic acid-containing polyester resins.

Examples of the catalyst-type curing agent include tertiary amine compounds such as benzyldimethylamine (BDMA) and 2,4,6-trisdimethylaminomethylphenol (DMP-30); Imidazole compounds such as 2-methylimidazole and 2-ethyl-4-methylimidazole (EMI24); And Lewis acids such as BF3 complexes.

Examples of the condensation-type curing agent include phenol resins having a methylol group such as a resol resin; A urea resin such as a urea resin containing a methylol group; And melamine resins such as methylol group-containing melamine resins.

When such other curing agent is used in combination, the lower limit of the content of the phenolic resin-based curing agent is preferably 20% by mass or more, more preferably 30% by mass or more, and more preferably 50% by mass or more based on the total curing agent (B) Particularly preferred. When the blend ratio is within the above range, good fluidity can be exhibited while maintaining flame resistance. The upper limit of the content of the phenol resin-based curing agent is not particularly limited, but is preferably 100 mass% or less based on the total curing agent (B).

The lower limit of the total content of the curing agent (B) relative to the fixing resin composition according to the present invention is not particularly limited, but is preferably 3% by mass or more, more preferably 3.5% by mass or more, Or more. When the lower limit of the mixing ratio is within the above range, good curability can be obtained. The upper limit value of the total content of the curing agent (B) relative to the fixing resin composition according to the present invention is not particularly limited, but is preferably 35% by mass or less based on the total amount of 100% by mass of the total fixing resin composition, And more preferably 15 mass% or less.

The phenol resin and the epoxy resin as the curing agent (B) are preferably such that the equivalent ratio (EP) / (OH) of the epoxy group number (EP) in the whole thermosetting resin (A) and the phenolic hydroxyl group number Or more and 1.3 or less. When the equivalent ratio is within the above range, sufficient curing characteristics can be obtained when the resulting fixing resin composition is molded.

[Inorganic filler (C)]

As the inorganic filler (C) used in the fixing resin composition according to the present invention, an inorganic filler generally used in the technical field of the fixing resin composition can be used. For example, fused silica such as fused silica and fused spherical silica, crystalline silica, alumina, kaolin, talc, clay, mica, lacquer, wollastonite, glass powder, glass flake, glass beads, glass fiber, A cured product of a molding material of an epoxy resin molding material or a molding material of an epoxy resin molding material is used as the molding material of the molding material of the present invention. And pulverized pulverized powder. Of these, silica such as fused silica, fused spherical silica and crystalline silica is preferable, and fumed spherical silica can be more preferably used. Among these, calcium carbonate is preferable from the viewpoint of cost. As the inorganic filler (C), one type may be used, or two or more types may be used in combination.

The average particle diameter D ₅₀ of the inorganic filler (C) is preferably 0.01 탆 or more and 75 탆 or less, and more preferably 0.05 탆 or more and 50 탆 or less. By setting the average particle diameter of the inorganic filler (C) within the above range, the filling ability of the hole portion and the magnet into the interspace (charging portion) is improved. Further, by setting the upper limit of the average particle diameter of the inorganic filler (C) to 75 m or less, the filling property is further improved.

The average particle diameter D ₅₀ was defined as an average volume-converted particle size by a laser diffraction type measuring device RODOS SR type (SYMPATEC HEROS & RODOS).

In the fixing resin composition according to the present invention, the inorganic filler (C) may contain two or more spherical silicas having different average particle diameters D ₅₀ . This makes it possible to improve both the fluidity and the filling property and the burr suppression.

The content of the inorganic filler (C) is preferably 50% by mass or more, more preferably 60% by mass or more, further preferably 65% by mass or more, and particularly preferably 60% by mass or more, relative to the total amount of 100% Is not less than 75% by mass. When the lower limit is within the above range, the increase in the moisture absorption amount and the decrease in the strength accompanying the curing of the resulting fixing resin composition can be reduced. The amount of the inorganic filler (C) is preferably 93 mass% or less, more preferably 91 mass% or less, and further preferably 90 mass% or less, based on the total value of 100 mass% of the fixing resin composition. When the upper limit is within the above range, the resulting fixing resin composition has good fluidity and good moldability. Therefore, the production stability of the rotor is enhanced, and a rotor excellent in balance between the production rate and the durability can be obtained.

Further, as a result of a study conducted by the inventors of the present invention, it has been found that when the content of the inorganic filler (C) is 50 mass% or more, the difference between the linear expansion coefficient and the linear expansion coefficient of the fixing member and the electromagnetic steel sheet is reduced, It was found that the deterioration of the rotation characteristics can be suppressed. In this way, a rotor excellent in durability, particularly in terms of persistence of rotation characteristics, is realized.

When silica such as fused silica, molten spherical silica, or crystalline silica is used as the inorganic filler (C), the content of silica is preferably 40 mass% or more with respect to the total value of 100 mass% of the fixing resin composition, More preferably at least% by mass. When the lower limit is within the above range, the balance between the fluidity and the coefficient of thermal expansion becomes good.

When an inorganic flame retardant such as zinc hydroxide, zinc molybdate or antimony trioxide is used in combination with the inorganic filler (C), metal hydroxides such as aluminum hydroxide and magnesium hydroxide as described later, and inorganic fillers Is preferably within the range of the content of the inorganic filler (C).

In addition, in this embodiment example described later, the sum of the inorganic filler and the inorganic flame retardant such as aluminum hydroxide is 80% by mass or more based on the total value of 100% by mass of the fixing resin composition. However, in the present invention, the content of the inorganic filler may be reduced and the content of the resin material may be increased in order to suitably adjust the fluidity and the coefficient of linear expansion to the member used in the rotor.

[Other components]

The fixing resin composition according to the present invention may contain a curing accelerator (D). The curing accelerator (D) is not particularly limited as long as it accelerates the reaction between the epoxy group of the epoxy resin and the hydroxyl group of the phenolic resin curing agent (B), and a commonly used curing accelerator (D) can be used.

Specific examples of the curing accelerator (D) include organic phosphorus compounds such as organic phosphine, tetra-substituted phosphonium compounds, phosphobetaine compounds, adducts of phosphine compounds and quinone compounds, adducts of phosphonium compounds and silane compounds Compound; Amidine-based compounds such as 1,8-diazabicyclo (5,4,0) undecene-7 and imidazole, tertiary amines such as benzyldimethylamine and the like, and also quaternary onium salts of the above compounds, And nitrogen atom-containing compounds represented by the following formula (1). From the viewpoint of curability, phosphorus atom-containing compounds are preferable. From the viewpoint of balance between fluidity and curability, tetra-substituted phosphonium compounds, phosphobetaine compounds, adducts of phosphine compounds and quinone compounds, phosphonium compounds and silane compounds And a curing accelerator having a latent property such as an adduct of a curing accelerator. From the viewpoint of fluidity, a tetra-substituted phosphonium compound is particularly preferable, and from the viewpoint of solder resistance, a phosphobetaine compound, adduct of a phosphine compound and a quinone compound is particularly preferable, and latent curing property In particular, adducts of a phosphonium compound and a silane compound are particularly preferred. From the viewpoint of continuous formability, a tetra-substituted phosphonium compound is preferable. In view of the cost, organic phosphine and nitrogen atom-containing compounds are also preferably used.

Examples of the organic phosphine which can be used in the fixing resin composition according to the present invention include primary phosphines such as ethylphosphine and phenylphosphine; A second phosphine such as dimethylphosphine or diphenylphosphine; And tertiary phosphines such as trimethylphosphine, triethylphosphine, tributylphosphine and triphenylphosphine.

Examples of the tetra-substituted phosphonium compound that can be used in the fixing resin composition according to the present invention include compounds represented by the following general formula (1).

[Chemical Formula 1]

In the general formula (1), P represents a phosphorus atom, R 1, R 2, R 3 and R 4 each independently represent an aromatic group or an alkyl group, A represents any of functional groups selected from a hydroxyl group, a carboxyl group and a thiol group AH represents an aromatic organic acid having at least one functional group selected from a hydroxyl group, a carboxyl group and a thiol group in at least one aromatic ring, x and y are each an integer of 1 to 4, 3, z is an integer of 0 to 3, and x = y.

The compound represented by the general formula (1) is obtained, for example, in the following manner, but is not limited thereto. First, a tetra-substituted phosphonium halide, an aromatic organic acid and a base are mixed with an organic solvent and uniformly mixed to generate an aromatic organic acid anion in the solution system. Subsequently, by adding water, the compound represented by the general formula (1) can be precipitated. In the compound represented by the general formula (1), R 1, R 2, R 3 and R 4 bonded to the phosphorus atom are phenyl groups and AH is a hydroxyl group in view of the excellent balance between the yield and the curing acceleration effect in the synthesis A phenolic compound, and A is preferably an anion of the phenolic compound. The phenol compounds include phenol, cresol, catechol, resorcinol, condensed polycyclic naphthol, dihydroxynaphthalene, bisphenol A, bisphenol S, bisphenol A, Biphenol, phenylphenol, phenol novolac, etc. Among them, a phenol compound having two hydroxyl groups is preferably used.

Examples of the phosphobetaine compound which can be used in the fixing resin composition according to the present invention include compounds represented by the following general formula (2).

(2)

In the general formula (2), X1 represents an alkyl group having 1 to 3 carbon atoms, Y1 represents a hydroxyl group, a represents an integer of 0 to 5, and b represents an integer of 0 to 4.

The compound represented by the general formula (2) is obtained, for example, as follows. First, a triazo-substituted phosphine, which is a third phosphine, is brought into contact with a diazonium salt to obtain a triazo-substituted phosphine and a diazonium group of the diazonium salt. However, it is not limited thereto.

Examples of adducts of a quinone compound and a phosphine compound which can be used in the fixing resin composition according to the present invention include compounds represented by the following general formula (3).

(3)

R5, R6 and R7 independently represent an alkyl group having 1 to 12 carbon atoms or an aryl group having 6 to 12 carbon atoms; R8, R9 and R10 independently represent hydrogen An atom or a hydrocarbon group of 1 to 12 carbon atoms, and R 8 and R 9 may be bonded to each other to form a ring.

Examples of the phosphine compound used in the addition of the phosphine compound and the quinone compound include triphenylphosphine, tris (alkylphenyl) phosphine, tris (alkoxyphenyl) phosphine, trinaphthylphosphine, tris Benzyl) phosphine or the like, or a substituent such as an alkyl group or an alkoxyl group is preferably present in the aromatic ring, and examples of the substituent such as an alkyl group and an alkoxyl group include those having a carbon number of 1 to 6. Triphenylphosphine is preferable from the standpoint of availability.

Examples of quinone compounds used in the addition of a phosphine compound and a quinone compound include o-benzoquinone, p-benzoquinone, and anthraquinone. Of these, p-benzoquinone is preferable from the viewpoint of storage stability .

As the method for producing the adduct of the phosphine compound and the quinone compound, the adduct can be obtained by contacting and mixing in a solvent in which both the organic tertiary phosphine and the benzoquinone can be dissolved. As the solvent, it is preferable that the solubility in the adduct is low in ketones such as acetone and methyl ethyl ketone. However, it is not limited thereto.

In the compound represented by the general formula (3), compounds in which R5, R6 and R7 bonded to the phosphorus atom are phenyl groups and R8, R9 and R10 are hydrogen atoms, that is, 1,4-benzoquinone and triphenylphosphine The added compound is preferable in that the cured product of the fixing resin composition lowers the elastic modulus at the time of heating.

Examples of adducts of the silane compound and the phosphonium compound which can be used in the fixing resin composition according to the present invention include compounds represented by the following general formula (4).

[Chemical Formula 4]

In the general formula (4), P represents a phosphorus atom, and Si represents a silicon atom. R11, R12, R13 and R14 independently represent an organic group or an aliphatic group having an aromatic ring or heterocyclic ring, and X2 is an organic group bonded to the groups Y2 and Y3. X3 is an organic group which combines with groups Y4 and Y5. Y2 and Y3 represent groups in which the proton donating group releases protons, and groups Y2 and Y3 in the same molecule bind to silicon atoms to form a chelate structure. Y4 and Y5 represent groups in which the proton donating group releases protons, and groups Y4 and Y5 in the same molecule bind to silicon atoms to form a chelate structure. X2 and X3 may be the same or different from each other, and Y2, Y3, Y4 and Y5 may be the same or different from each other. Z1 is an organic group having an aromatic ring or heterocyclic ring, or an aliphatic group.

Examples of R11, R12, R13 and R14 in the general formula (4) include a phenyl group, a methylphenyl group, a methoxyphenyl group, a hydroxyphenyl group, a naphthyl group, a hydroxynaphthyl group, a benzyl group, Butyl group, n-octyl group and cyclohexyl group. Among them, aromatic group or unsubstituted aromatic group having a substituent such as phenyl group, methylphenyl group, methoxyphenyl group, hydroxyphenyl group or hydroxy naphthyl group is preferable More preferable.

In the general formula (4), X2 is an organic group bonded to Y2 and Y3. Similarly, X3 is an organic group which combines with groups Y4 and Y5. Y2 and Y3 are groups in which the proton donating group releases protons, and groups Y2 and Y3 in the same molecule bind to silicon atoms to form a chelate structure. Similarly, Y 4 and Y 5 are groups in which the proton donating group releases protons, and groups Y 4 and Y 5 in the same molecule bind to silicon atoms to form a chelate structure. The groups X2 and X3 may be the same or different from each other, and the groups Y2, Y3, Y4 and Y5 may be the same or different from each other. The group represented by -Y2-X2-Y3- and -Y4-X3-Y5- in the general formula (4) is composed of a group in which the proton donor is formed by releasing two protons. The proton donor is preferably an organic acid having at least two carboxyl groups or hydroxyl groups in the molecule and an aromatic compound having at least two carboxyl groups or hydroxyl groups on the carbon constituting the aromatic ring. And an aromatic compound having at least two hydroxyl groups on adjacent carbon atoms constituting it is more preferable. For example, there may be mentioned catechol, pyrogallol, 1,2-dihydroxynaphthalene, 2,3-dihydroxynaphthalene, 2,2'-biphenol, 1,1'-bi-2-naphthol, salicylic acid, 2-naphthoic acid, 3-hydroxy-2-naphthoic acid, chloranilic acid, tannic acid, 2-hydroxybenzyl alcohol, 1,2-cyclohexanediol, . Among them, catechol, 1,2-dihydroxynaphthalene and 2,3-dihydroxynaphthalene are more preferable from the viewpoint of ease of raw material availability and balance of curing acceleration effect.

Z1 in the general formula (4) represents an organic group or an aliphatic group having an aromatic ring or heterocyclic ring, and specific examples thereof include aliphatic hydrocarbon groups such as a methyl group, an ethyl group, a propyl group, a butyl group, a hexyl group and an octyl group , Aromatic hydrocarbon groups such as a phenyl group, a benzyl group, a naphthyl group and a biphenyl group, and reactive substituents such as a glycidyloxypropyl group, a mercaptopropyl group, an aminopropyl group and a vinyl group. Among these, , A phenyl group, a naphthyl group and a biphenyl group are more preferable in terms of thermal stability.

As a method for producing adducts of a phosphonium compound and a silane compound, a silane compound such as phenyltrimethoxysilane or a proton donor such as 2,3-dihydroxynaphthalene is added and dissolved in a flask containing methanol, followed by stirring at room temperature A sodium hypochlorite-methanol solution is added dropwise. Further, a solution prepared by dissolving tetra-substituted phosphonium halide such as tetraphenylphosphonium bromide prepared in advance in methanol therein is added dropwise with stirring at room temperature to precipitate crystals. The precipitated crystals are filtered, washed with water and vacuum-dried to obtain an adduct of a phosphonium compound and a silane compound. However, it is not limited to this.

The lower limit of the content of the curing accelerator (D) which can be used in the fixing resin composition according to the present invention is preferably 0.1% by mass or more with respect to the total value of 100% by mass of the total fixing resin composition. When the lower limit of the content of the curing accelerator (D) is within the above range, sufficient curability can be obtained. The upper limit of the content of the curing accelerator (D) is preferably 3% by mass or less, more preferably 1% by mass or less, based on the total value of 100% by mass of the total fixing resin composition. When the upper limit of the content of the curing accelerator (D) is within the above range, sufficient fluidity can be obtained.

The resin composition for fixation of the present invention may further contain a compound (E) (hereinafter occasionally referred to simply as "compound (E)") having a hydroxyl group bonded to two or more adjacent carbon atoms constituting an aromatic ring . The compound (E) having a hydroxyl group bonded to two or more adjacent carbon atoms constituting the aromatic ring can be used as a curing accelerator (D) for accelerating the crosslinking reaction between the epoxy resin (A1) and the phenol resin curing agent (B) Even when a phosphorus atom-containing curing accelerator which does not have latency is used, the reaction during the melt-kneading of the fixing resin composition can be suppressed and the fixing resin composition can be stably obtained. Compound (E) also has an effect of improving the fluidity by lowering the melt viscosity of the fixing resin composition. As the compound (E), a monocyclic compound represented by the following general formula (5) or a multicolour type compound represented by the following general formula (6) may be used, and these compounds may have a substituent other than a hydroxyl group.

[Chemical Formula 5]

In the formula (5), when either one of R15 and R19 is a hydroxyl group and one of them is a hydroxyl group, the other is a substituent other than a hydrogen atom, a hydroxyl group or a hydroxyl group, and R16, R17 and R18 represent a hydrogen atom, Lt; / RTI >

[Chemical Formula 6]

R21, R22, R23, R24 and R25 are each a hydrogen atom, a hydroxyl group or a hydroxyl group, and the other is a hydrogen atom, a hydroxyl group or a hydroxyl group, when either one of R20 and R26 in the general formula (6) A hydroxyl group or a hydroxyl group.

Specific examples of monocyclic compounds represented by the general formula (5) include, for example, catechol, pyrogallol, gallic acid, gallic acid esters or derivatives thereof. Specific examples of the polycyclic compound represented by the general formula (6) include, for example, 1,2-dihydroxynaphthalene, 2,3-dihydroxynaphthalene and derivatives thereof. Among these, compounds in which a hydroxyl group is bonded to two adjacent carbon atoms constituting an aromatic ring are preferable in that the control of flowability and curability is easy. Further, in consideration of volatilization in the kneading step, it is more preferable that the mother nucleus is a naphthalene ring compound having low volatility and high stability of weighing. In this case, the compound (E) can specifically be a compound having a naphthalene ring such as 1,2-dihydroxynaphthalene, 2,3-dihydroxynaphthalene and a derivative thereof. These compounds (E) may be used alone or in combination of two or more.

The lower limit of the content of the compound (E) is preferably 0.01% by mass or more, more preferably 0.03% by mass or more, and particularly preferably 0.05% by mass or more based on the total amount of 100% by mass of the total fixing resin composition. When the lower limit of the content of the compound (E) is within the above range, the fixing resin composition can have a sufficiently low viscosity and an effect of improving fluidity. The upper limit of the content of the compound (E) is preferably 2% by mass or less, more preferably 0.8% by mass or less, and particularly preferably 0.5% by mass or less, based on the total amount of 100% by mass of the total fixing resin composition. When the upper limit of the content of the compound (E) is within the above range, there is little possibility of lowering the curing property of the fixing resin composition or lowering the physical properties of the cured product.

In the fixing resin composition according to the present invention, a coupling agent (F) such as a silane coupling agent may be added to improve the adhesion between the epoxy resin (A1) and the inorganic filler (C). The coupling agent (F) is not particularly limited as long as it reacts between the epoxy resin (A1) and the inorganic filler (C) to improve the interface strength between the epoxy resin (A1) and the inorganic filler (C) For example, epoxy silane, aminosilane, ureido silane, mercaptosilane, and the like. In addition, the coupling agent (F) may be used in combination with the above-mentioned compound (E) to increase the effect of the compound (E) which improves the fluidity by lowering the melt viscosity of the fixing resin composition.

Examples of the epoxy silane include? -Glycidoxypropyltriethoxysilane,? -Glycidoxypropyltrimethoxysilane,? -Glycidoxypropylmethyldimethoxysilane,? - (3,4-epoxycyclohexyl ) Ethyltrimethoxysilane, and the like. Examples of the aminosilane include γ-aminopropyltriethoxysilane, γ-aminopropyltrimethoxysilane, N-β (aminoethyl) γ-aminopropyltrimethoxysilane, N- )? -aminopropyltrimethoxysilane, N-phenyl? -aminopropyltriethoxysilane, N-phenyl? -aminopropyltrimethoxysilane, N-? (aminoethyl) N-6- (aminohexyl) 3-aminopropyltrimethoxysilane, and N- (3- (trimethoxysilylpropyl) -1,3-benzenedimethanone. For example, γ-ureidopropyltriethoxysilane, hexamethyldisilazane, etc. As a potential amino silane coupling agent protected by reacting a primary amino moiety of an aminosilane with a ketone or an aldehyde As the aminosilane, a secondary amino group may also be contained. [0040] In addition, mercaptosilane Include, for example, bis (3-triethoxysilylpropyl) tetrasulfide, bis (3-triethoxysilylpropyl) tetrasulfide in addition to γ- ) And a silane coupling agent which exhibits the same function as the mercaptosilane coupling agent by thermal decomposition such as disulfide, etc. These silane coupling agents may be blended in advance with hydrolysis reaction. These may be used singly or in combination of two or more.

From the viewpoint of continuous formability, mercaptosilane is preferable, and aminosilane is preferable from the viewpoint of fluidity, and epoxy silane is preferable from the viewpoint of adhesion.

The lower limit of the content of the coupling agent (F) such as silane coupling agent that can be used in the fixing resin composition according to the present invention is preferably 0.01% by mass or more based on the total value of 100% by mass of the total fixing resin composition, Preferably 0.05 mass% or more, and particularly preferably 0.1 mass% or more. When the lower limit of the content of the coupling agent (F) such as the silane coupling agent is within the above range, the interface strength between the epoxy resin (A1) and the inorganic filler (C) is not lowered and good vibration proofing property can be obtained. The upper limit of the content of the coupling agent (F) such as a silane coupling agent is preferably 1% by mass or less, more preferably 0.8% by mass or less, particularly preferably 100% by mass or less based on the total amount of 100% By mass is not more than 0.6% by mass. When the upper limit of the content of the coupling agent (F) such as the silane coupling agent is within the above range, the interface strength between the epoxy resin (A1) and the inorganic filler (C) is not lowered and good vibration proofing property can be obtained. When the content of the coupling agent (F) such as the silane coupling agent is within the above range, the water absorbency of the cured product of the fixing resin composition is not increased, and good rustproofing property can be obtained.

In the fixing resin composition according to the present invention, an inorganic flame retardant (G) may be added to improve flame retardancy. Among them, a metal hydroxide or a composite metal hydroxide which inhibits the combustion reaction by dehydration and endothermic combustion at the time of combustion is preferable in that the combustion time can be shortened. Examples of the metal hydroxide include aluminum hydroxide, magnesium hydroxide, calcium hydroxide, barium hydroxide and zirconia hydroxide. The composite metal hydroxide is a hydrotalcite compound containing at least two metal elements, wherein at least one metal element is magnesium and the other metal elements are calcium, aluminum, tin, titanium, iron, cobalt, nickel, copper , Or zinc. As such a composite metal hydroxide, a magnesium hydroxide / zinc solid solution is easily available as a commercial product. Among them, aluminum hydroxide, magnesium hydroxide and zinc solid solution are preferable from the viewpoint of continuous formability. The inorganic flame retardant (G) may be used alone or in combination of two or more. For the purpose of reducing the influence on the continuous formability, surface treatment may be carried out using a silicon compound such as a silane coupling agent or an aliphatic compound such as wax.

The content of the inorganic flame retardant (G) according to the present invention is preferably 1% by mass or more and 20% by mass or less, more preferably 3% by mass or more, relative to the total amount of 100% by mass of the fixing resin composition related to the present invention , 10 mass% or less.

In the fixing resin composition according to the present invention, the upper limit of the ionic impurity concentration is preferably 500 ppm or less, more preferably 300 ppm or less, and even more preferably 200 ppm or less, with respect to the fixing resin composition. The lower limit of the ionic impurity concentration is not particularly limited, but is, for example, 0 ppb or more, more preferably 10 ppb or more, and more preferably 100 ppb or more, relative to the fixing resin composition according to the present invention. As a result, when a cured product of the fixing resin composition according to the present invention is used for a fixing member, high rust-inhibiting properties can be maintained even under high temperature and high humidity conditions.

Examples of the ionic impurities related to the present invention include, but are not limited to, alkali metal ions, alkaline earth metal ions, and halogen ions, more specifically, sodium ions and chloride ions. The upper limit of the sodium ion concentration is preferably 100 ppm or less, more preferably 70 ppm or less, and even more preferably 50 ppm or less, with respect to the fixing resin composition according to the present invention. The upper limit of the chloride ion concentration is preferably 100 ppm or less, more preferably 50 ppm or less, and even more preferably 30 ppm or less, with respect to the fixing resin composition according to the present invention. By setting the thickness within the above range, corrosion of the electromagnetic steel sheet and the magnet can be suppressed.

In the present embodiment, for example, by using an epoxy resin having high purity, ionic impurities can be reduced. Thus, a rotor having excellent durability can be obtained.

The concentration of ionic impurities can be determined as follows. First, the fixing resin composition according to the present invention is molded and cured at 175 DEG C for 180 seconds, and then pulverized by a pulverizer to obtain a cured product powder. The obtained hard powder is treated in pure water at 120 DEG C for 24 hours to extract ions in purified water and then measured using ICP-MS (inductively coupled plasma ion mass spectrometer).

In the fixing resin composition according to the present invention, the upper limit of the content of alumina is preferably 10% by mass or less, more preferably 7% by mass or less, relative to the total amount of 100% by mass of the fixing resin composition, Is not more than 5% by mass. The lower limit of the content of alumina is not particularly limited, but is preferably 0% by mass or more, more preferably 0.01% by mass or more, more preferably 0.01% by mass or more, based on 100% by mass of the total amount of the fixing resin composition of the present invention Is not less than 0.1% by mass. By setting the content of alumina to the upper limit value or less, the fluidity of the fixing resin composition according to the present invention can be improved and the weight can be reduced. In the present embodiment, 0 mass% allows a value of the detection limit.

In the fixing resin composition according to the present invention, in addition to the above-mentioned components, hydrotalcites or ion scavengers such as hydrous oxides of elements selected from magnesium, aluminum, bismuth, titanium and zirconium; Coloring agents such as carbon black, spinach and titanium oxide; Natural waxes such as carnauba wax; Synthetic waxes such as polyethylene wax; Higher fatty acids such as stearic acid and zinc stearate, and metal salts thereof or release agents such as paraffin; A low-stress agent such as a polybutadiene compound, an acrylonitrile-butadiene copolymer compound, a silicone oil, or a silicone compound such as silicone rubber may be appropriately blended.

The content of the colorant according to the present invention is preferably 0.01 mass% or more and 1 mass% or less, more preferably 0.05 mass% or more and 0.8 mass% or less, Or less. When the content of the colorant is within the above range, a step of removing the colored impurities is not required, and workability is improved. Therefore, a rotor having an excellent production rate is realized.

The content of the releasing agent related to the present invention is not particularly limited, but is preferably 0.01% by mass or more, more preferably 0.05% by mass or less, and still more preferably 0.05% by mass or less, relative to the total amount of 100% by mass of the fixing resin composition related to the present invention. , And the upper limit is, for example, preferably 1% by mass or less, more preferably 0.5% by mass or less, further preferably 0.2% by mass or less, and particularly preferably 0.1% by mass or less. It is generally known that when a semiconductor chip is transferred, a releasing agent is added in a certain amount in order to ensure releasability of the fixing member to be separated from the mold. However, if the addition amount of the releasing agent is excessively large, the adhesion between the fixing member and the electromagnetic steel sheet may be deteriorated. Therefore, in the present invention, the content of the releasing agent is preferably small, more preferably 0.2 mass% or less. As a result, the adhesion between the fixing member and the electromagnetic steel plate can be enhanced, and thus a rotor excellent in durability can be realized.

The content of the low stress agent related to the present invention is preferably 0.01% by mass or more and 3% by mass or less, more preferably 0.05% by mass or more, and 2% by mass or less, % Or less.

When the fixing resin composition of the present invention is configured as described above, it becomes possible to improve the filling characteristics of the fixing resin composition. Even when the gap between the hole and the magnet is narrow, the adhesion area between the steel plate and the magnet can be sufficiently secured. As a result, high mechanical strength can be imparted to the rotor. In addition, even when immersed in an automatic transmission fluid (ATF), the weight change rate and the volume change rate before and after immersion can be suppressed to be small, and therefore, the rotor is highly desirable as a rotor used in automotive applications.

In the fixing resin composition relating to the present invention, the resin for fixing to the flow path having a cross-sectional shape of 3 mm in width and 80 占 퐉 in thickness at a mold temperature of 175 占 폚, a molding pressure of 6.9 MPa, an injection time of 20 seconds and a curing time of 90 seconds The slit flow length when the composition is injected has a lower limit value of preferably 75 mm or more, more preferably 80 mm or more, still more preferably 85 mm or more, and the upper limit value is preferably 300 mm or less. By setting the slit length of 80 占 퐉 to be equal to or larger than the lower limit, the charging characteristic to the gap in the compromised region can be enhanced. When the slit length of 80 탆 in thickness is made the upper limit value or less, a large amount of burrs are adhered to the rotor, so that burrs are broken when the rotor is rotated, so that it is possible to suppress the burr from inhibiting the rotation of the rotor.

In the present embodiment, the length of the slit flow can be increased by, for example, making the particle size of the filler small, reducing the softening point of the epoxy resin and / or the curing agent, or reducing the amount of the curing accelerator.

The lower limit of the viscosity when measured at a measurement temperature of 175 ° C and a load of 10 kg using an apparatus for measuring fixed viscosity of the fixing resin composition according to the present invention is not particularly limited, but is preferably 3 Pa · s or more , More preferably not less than 5 Pa · s, still more preferably not less than 6 Pa · s, and the upper limit value is not particularly limited, but is not more than 50 Pa · s, more preferably not more than 30 Pa · s, Is not more than 15 Pa · s. If it is more than the lower limit value, occurrence of voids due to mixing at the time of molding can be suppressed. If it is not more than the upper limit value, good filling property can be obtained. As a result, a rotor excellent in manufacturing stability is realized.

In addition, in the present embodiment, for example, the above-mentioned high-viscosity viscosity can be reduced by lowering the softening point of the epoxy resin and the curing agent, by using a latent curing accelerator, or by using the molten spherical silica as the filler.

The gel time at 175 캜 of the fixing resin composition according to the present invention is preferably 10 seconds or more and 50 seconds or less, more preferably 15 seconds or more and 45 seconds or less. If it is more than the lower limit value, the filling property can be improved. Below the upper limit, the molding cycle can be accelerated.

In the present embodiment, the gel time can be reduced by increasing the amount of the curing accelerator, for example. As a result, a rotor excellent in manufacturing stability is realized.

The spiral flow of the fixing resin composition according to the present invention is preferably 50 cm or more, more preferably 60 cm or more, and further preferably 80 cm or more. If it is more than the lower limit value, the filling property, especially the filling property in the vertical direction, can be improved. The upper limit of the spiral flow is not particularly limited, but is preferably 250 cm or less, more preferably 220 cm or less. As a result, a rotor excellent in manufacturing stability is realized.

In addition, in the present embodiment, the spiral flow can be increased by using, for example, fused spherical silica as a filler, lowering the softening point of the epoxy resin and the curing agent, or reducing the amount of the curing accelerator.

When the curing torque of the fixing resin composition according to the present invention was measured at a measurement temperature of 175 ° C over a period of 60 seconds after the start of measurement, the cured torque was measured at T ₆₀ , when the value of maximum cure torque as T _max, preferably maximum cure torque value ratio T ₆₀ / T _max (%) value measures the start of the cured torque 60 seconds for up to after 300 seconds start of the measurement is greater than or equal to 40% and 45% , And more preferably 50% or more. The upper limit of the ratio of the cured torque value is not particularly limited, but is preferably 100% or less, and more preferably 95% or less. If the lower limit is more than the lower limit, productivity can be expected to be improved.

In the present embodiment, the ratio of the cured torque value can be increased by increasing the amount of the curing accelerator, for example. As a result, a rotor excellent in manufacturing stability is realized.

The fixing resin composition according to the present invention is first produced with a dumbbell-shaped cured product of the fixing resin composition obtained according to JIS K7162 under a curing condition of a mold temperature of 175 deg. C, an injection pressure of 9.8 MPa, and a curing time of 120 seconds . The cured product of the dumbbell-shaped fixing resin composition is further cured at 175 DEG C for 4 hours to prepare a test piece. The test piece was subjected to a tensile test under the conditions of a temperature of 25 DEG C and a load speed of 1.0 mm / min to obtain fracture energy. In addition, the same shape as the dumbbell shape described in JIS K7162 is described in ISO 527-2.

Hereinafter, the breaking energy obtained when the tensile test is carried out under the conditions of a temperature of 25 DEG C and a load speed of 1.0 mm / min is defined as a breaking energy a. The breaking energy obtained when the tensile test is carried out under the conditions of a temperature of 150 DEG C and a load speed of 1.0 mm / min is defined as a breaking energy b. The breaking strength in the measurement conditions of the breaking energy a is defined as the breaking strength a, and the breaking strength in the measurement conditions of the breaking energy b is taken as the breaking strength b.

The breaking energy is calculated by creating a curve (stress-strain curve) that shows the relationship between the normal stress and the strain at the time of the tensile test.

Specifically, strain is a variable, and the integrated value of the stress from the start point to the breaking point of the tensile test is calculated. The larger the breaking energy is, the more excellent the durability of the obtained rotor core is because of the hardness and strong tackiness. In addition, the unit is x 10 ^-4 J / min.

The breaking energy a of the cured product (fixing member) of the fixing resin composition according to the present invention is preferably 1.5 x 10 < ^-4 > J / min or more. By having the breaking energy a in this range, a rotor core having excellent durability with hardness and strong tackiness can be obtained.

It is more preferable that the breaking energy a is 1.9 x 10 < ^-4 > J / min or more. When the breaking energy a is in this range, it is possible to realize a rotor core exhibiting sufficient durability under an environment of high-speed rotation for a long time at a high temperature. The upper limit value is not particularly limited, but 15.0 x 10 < ^-4 > J / min is sufficient.

The breaking energy b is preferably 1.2 x 10 < ^-4 > J / min or more. When the breaking energy b measured at a high temperature as compared with the breaking energy a is within the above range, it is possible to obtain a rotor that is resistant to temperature change and has excellent durability with hardness and strong tackiness. It is more preferable that the breaking energy b is 1.5 x 10 < ^-4 > J / min or more. When the breaking energy b is in this range, the durability at the time of high-speed rotation is further improved. The breaking energy b is not particularly limited to the upper limit value similarly to the breaking energy a, but it is sufficient that the fracture energy b is about 8.0 x 10 ^-4 J / cm.

In order to improve the breaking energy a and b, the following method is effective.

First, by using a combination of the epoxy resin and the curing agent relating to the present invention, the strength and the strong adhesiveness of the resin component can be improved. In addition to this, it is more preferable to modify the surface of the inorganic filler with a silane coupling agent to improve the interface bonding strength between the resin and the inorganic filler. Further, it is more preferable that the microcracks generated in the resin cured product are not well developed by adjusting the particle size distribution of the inorganic filler.

The rotor according to the present embodiment can further improve durability by controlling the breaking strength a of the cured product (fixing member) of the fixing resin composition according to the present invention to be in the range of 50 MPa or more. Specifically, when the breaking strength a is in this range, the durability at the time of high-speed rotation is further improved. The breaking strength a is preferably 60 MPa or more. Although the upper limit value is not particularly limited, about 200 MPa is sufficient.

The breaking strength b of the cured product of the fixing resin composition according to the present invention is controlled to be in the range of 15 MPa or more similarly to the breaking strength a so that the durability at the time of high-speed rotation is further improved. The breaking strength b is preferably 20 MPa or more. Although the upper limit value is not particularly limited, about 100 MPa is sufficient.

By setting the breaking strengths a and b to the above specific ranges, it is possible to provide a rotor having excellent durability. Particularly, it is possible to provide a rotor excellent in the positional stability of the permanent magnet at the time of using the rotor at high speed rotation.

The fixing resin composition according to the present invention was injection-molded using a molding machine under the conditions of a mold temperature of 175 占 폚, an injection pressure of 9.8 MPa, and a curing time of 120 seconds to prepare a fixing resin composition having a length of 80 mm, a width of 10 mm, Mm < / RTI > The molded product is further cured at 175 DEG C for 4 hours to produce a cured product. Thereafter, the cured product is immersed in ATF at 150 DEG C for 1000 hours. The weight change ratio [%] is calculated by (X2-X1) / X1 100 when the weight of the cured product before immersing ATF is X1 and the weight of the cured product after immersing ATF is X2.

Here, ATF is not particularly limited as long as it is generally used, and various additives are added to the base oil. Here, the base oil is a mineral base base oil, a synthetic base base oil, or a mixture thereof. Examples of the additive component include viscosity adjusters and friction modifiers.

In the present embodiment, for example, Matfluid D (manufactured by Nissan Motors), Auto Fluid type T-IV (manufactured by Toyota Motor Corporation), ATF DW-1 (manufactured by Honda Motor Co., Ltd.) .

The fixing resin composition according to the present invention preferably has a weight change rate of not more than 0.5% when the cured product (fixing member) is immersed in ATF at 150 DEG C for 1000 hours. More preferably, it is 0.2% or less. Since the rate of weight change before and after ATF immersion is not more than the upper limit value, it is possible to prevent the fixing member from being greatly swollen by the lubricating oil even if the fixing member comes into contact with the lubricating oil at a high temperature for a long time.

It is also preferable that the fixing resin composition according to the present invention has a weight change rate of -0.05% or more when the cured product is immersed in ATF at 150 DEG C for 1000 hours. More preferably, it is -0.03% or more. Since the rate of weight change before and after immersion of the ATF is equal to or more than the lower limit value, it is possible to prevent a part of the fixing member from flowing out into the lubricating oil even if the fixing member contacts the lubricating oil at a high temperature for a long time. Also, since the rate of weight change before and after ATF immersion is equal to or higher than the lower limit value described above, deterioration of the lubricating oil characteristics can be suppressed.

Therefore, the weight change rate before and after ATF immersion is within the above-mentioned range, so that the dimension of the fixing member can be kept constant even in an environment of high speed rotation for a long time at a high temperature. As a result, since the position of the magnet can be kept constant over a long period of time, a rotor excellent in long-term reliability can be obtained.

When the cured product of the present invention is immersed in ATF at 150 DEG C for 2000 hours and the weight of the cured product after immersing ATF is taken as X3, the fixing resin composition according to the present invention is expressed by (X3-X1) / X1 x 100 The calculated weight change rate [%] is preferably -0.1% or more and 0.6% or less. More preferably, it is -0.07% or more and 0.5% or less. If the weight change rate measured under the above conditions is within the above range, it is possible to obtain a rotor having better long-term reliability even in an environment of high-speed rotation for a long time at a high temperature.

When the cured product of the fixing resin composition according to the present invention is immersed in ATF at 150 DEG C for 1000 hours, the volume of the cured product before immersion in ATF is Y1 and the volume of the cured product after immersion in ATF is defined as Y2 , The volume change ratio [%] calculated by (Y2-Y1) / Y1 x 100 is preferably -0.2% or more and 1.5% or less. More preferably, it is -0.1% or more and 1% or less. When the rate of volume change measured under the above conditions is within the above range, a rotor with better long-term reliability can be obtained even under an environment of high-speed rotation at a high temperature for a long time.

The fixing resin composition according to the present invention is uniformly mixed at room temperature using, for example, a mixer, and then melt-kneaded using a kneader such as a heating roll, a kneader or an extruder if necessary, By cooling and pulverizing, the desired dispersion degree, fluidity and the like can be adjusted.

The method for producing the fixing resin composition according to the present invention is not particularly limited, but it can be carried out as follows.

First, a predetermined amount of a thermosetting resin (A), a phenol resin-based curing agent (B), an inorganic filler (C), and preferably other additives are mixed to obtain a fixing resin composition. Subsequently, the mixture is uniformly pulverized and mixed at room temperature using, for example, a mixer, a jet mill, a ball mill, etc., and then heated to about 90 to 120 ° C using a kneader such as a heating roll, a kneader or an extruder Melting and kneading are carried out. Subsequently, the fixing resin composition after kneading is cooled and pulverized to obtain a solid fixing resin composition in the form of granules or powder. The particle size of the powder or granules of the fixing resin composition according to the present invention is preferably 5 mm or less, for example. 5 mm or less, it is possible to suppress the increase in the mass deviation of the tablet due to the occurrence of defective filling at the time of tableting.

In addition, a tablet can be obtained by tablet-forming powders or granules of the obtained fixing resin composition. As the device used for the tablet molding, a single-shot type or multi-row rotary type tablet can be used. The shape of the tablet is not particularly limited, but a cylindrical shape is preferable. There is no particular limitation on the temperature of the male mold, the female mold, and the environment of the tablet machine, but 35 ° C or lower is preferable. If the temperature exceeds 35 ° C, the viscosity of the fixing resin composition may increase due to the reaction, and the fluidity may be deteriorated. The pressing pressure is preferably in the range of 400 × 10 ^{4 to 3} × 10 ⁴ Pa. By making the tableting pressure lower than the above-mentioned upper limit value, it is possible to suppress breakage immediately after tableting. On the other hand, by making the tableting pressure equal to or higher than the lower limit described above, sufficient cohesive force can not be obtained, so that destruction of the tablet during transportation can be suppressed. There are no particular limitations on the material and surface treatment of the male and female molds of the tablet machine, and those of known materials can be used. Examples of the surface treatment include electric discharge machining, coating of release agent, plating treatment, have.

The fixing member according to the present invention preferably has a glass transition temperature (Tg) of 130 캜 or higher, more preferably 140 캜 or higher. If the lower limit value is not less than the lower limit value, the reliability improvement can be expected. The upper limit of the glass transition temperature (Tg) is not particularly limited, but is preferably 200 DEG C or lower, more preferably 190 DEG C or lower. This realizes a rotor with excellent durability.

In the present embodiment, the glass transition temperature (Tg) can be increased by increasing the softening point of, for example, the epoxy resin and the curing agent.

The fixing member according to the present invention preferably has a bending strength at 150 캜 of 70 MPa or more, more preferably 100 MPa or more. If it is more than the lower limit value, cracks or the like hardly occurs and reliability improvement can be expected. The upper limit of the bending strength is not particularly limited, but is preferably 300 MPa or less, and more preferably 250 MPa or less. This realizes a rotor with excellent durability.

In the present embodiment, the bending strength can be increased by treating the surface of the filler with a coupling agent, for example.

The upper limit of the flexural modulus at 150 캜 of the fixing member according to the present invention is preferably 1.6 x 10 ⁴ MPa or less and more preferably 1.3 x 10 ⁴ MPa or less. If it is less than the upper limit, improvement in reliability due to stress relaxation can be expected. The lower limit of the bending elastic modulus is not particularly limited, but is preferably 5000 MPa or more, more preferably 7000 MPa or more. This realizes a rotor with excellent durability.

In the present embodiment, for example, the bending elastic modulus can be reduced by increasing the addition amount of the low stress agent or by reducing the amount of the filler to be blended.

The coefficient of linear expansion (? 1) of the fixing member according to the present invention in the region of not lower than 25 占 폚 and not higher than the glass transition temperature (Tg) is preferably not lower than 10 ppm / 占 폚 and not higher than 25 ppm / More preferably 20 ppm / ° C or less. Within the above range, the difference in thermal expansion from the electromagnetic steel sheet is small and the magnet can be prevented from being lost. This realizes a rotor with excellent durability.

In the present embodiment, the linear expansion coefficient? 1 can be reduced by increasing the amount of filler, for example.

The coefficient of linear expansion (? 2) of the fixing member according to the present invention in the region of 25 占 폚 or higher and the glass transition temperature (Tg) or lower is preferably 10 ppm / 占 폚 or higher and 100 ppm / 占 폚 or lower, more preferably 20 ppm / More preferably 80 ppm / ° C or lower. Within the above range, the difference in thermal expansion from the electromagnetic steel sheet is small and the magnet can be prevented from being lost. This realizes a rotor with excellent durability.

Further, in the present embodiment, for example, by increasing the amount of filler to be added, the coefficient of linear expansion? 2 can be reduced.

(Manufacturing method of rotor)

The method of manufacturing the rotor 100 according to the present embodiment includes a rotor core 110 in which a plurality of holes 150 are formed along the periphery of a through hole through which a rotating shaft (shaft 170) A step of inserting the magnet 120 into the hole 150, a step of filling the cavity 150 of the hole 150 and the magnet 120 with a resin composition for fixation, a step of curing the resin composition And a step of inserting the shaft 170 into the through hole of the rotor core 110 and fixing and fixing the shaft 170 to the rotor core.

In the present embodiment, insert molding is preferably used as a method for filling the fixing resin composition. Hereinafter, this will be described in detail.

First, the insert molding apparatus will be described.

2 is a sectional view of an upper mold 200 of an insert molding apparatus used for insert molding.

As an example of the method of forming the fixing member 130, a method of performing insert molding using the fixing resin composition on the tablet can be used. For this insert molding, an insert molding apparatus is used. This molding apparatus comprises a top mold 200 having a port 210 to which a fixing resin composition on a tablet is supplied and a flow path 220 for moving a fixing resin composition in a molten state, a lower mold, Heating means for heating the lower mold, and an extrusion mechanism for pushing out the resin composition for fixing in a molten state. The insert molding apparatus may, for example, be provided with a carrying function for carrying a rotor core or the like.

In this embodiment, the upper die 200 and the lower die are preferably in close contact with the upper and lower surfaces of the rotor core 110 (that is, one surface of the electromagnetic steel sheet constituting the rotor core 110). For example, desirable. The upper mold 200 and the lower mold according to the present embodiment do not cover the entirety of the rotor core 110 and do not cover a part of the side surface of the rotor core 110. For example, It is different. The mold for transfer formation is configured so that the entire semiconductor chip is disposed in a cavity composed of an upper mold and a lower mold.

The port 210 may have two oil passages 220 or a Y-shaped oil passage 220. As a result, the two resin moldings can be charged from the one port 210 to the two hole portions. In addition, one port may have one flow path for filling the resin composition for fixation into one hole portion, but it may have three flow paths for filling the resin composition for fixation in three or more holes. However, the plurality of flow paths may be independent from each other, but they may be continuous.

Next, the insert molding according to the present embodiment will be described.

First, the rotor core is pre-heated in an oven, a heat plate, or the like, and fixed to a lower mold of a molding apparatus not shown. Subsequently, the magnet is inserted into the hole portion of the rotor core. Subsequently, the lower mold is raised to press the upper mold 200 on the upper surface of the rotor core. Thus, the upper and lower surfaces of the rotor core 110 are sandwiched between the upper mold 200 and the lower mold. At this time, the leading end of the flow path 220 in the upper mold 200 is disposed on the hollow portion of the hole and the magnet. In addition, the rotor core is heated by heat conduction from the lower mold of the molding apparatus and the upper mold 200. The lower mold and the upper mold 200 of the molding apparatus are temperature-controlled, for example, at about 150 ° C to 200 ° C so that the rotor core has a temperature suitable for molding and curing of the fixing resin composition. In this state, the fixing resin composition on the tablet is supplied into the port 210 of the upper mold 200. The resin composition for fixing on the tablet supplied in the port 210 of the upper mold 200 is heated in the port 210 to be melted.

Subsequently, the resin composition for fixing in the molten state is pushed out from the port 210 by a plunger (extrusion mechanism). Then, the fixing resin composition moves through the flow path 220 and is filled in the hole portion and the gap portion of the magnet. In the meantime, the rotor core is heated by the heat conduction from the mold (lower mold and upper mold 200), and the fixed fixing resin composition is cured to form the fixing member. At this time, the temperature condition may be, for example, 150 to 200 占 폚. The curing time may be, for example, 30 seconds to 180 seconds. Thereby, the magnet 120 inserted into the hole portion 150 is fixed by the fixing member 130. Thereafter, the upper mold 200 is separated from the upper surface of the rotor core. Next, the shaft 170 is inserted into the through hole of the rotor core 110, and the shaft 170 is fixed to the rotor core.

Thus, the rotor of the present embodiment is obtained.

Here, the insert molding method of the present embodiment is different from the transfer molding method used for manufacturing a semiconductor device from the viewpoint that demoulding is not necessary.

In the insert molding method, the upper surface of the rotor core 110 and the upper mold 200 are in close contact with each other, and the holes of the rotor core 110 are filled with resin through the flow path of the upper mold 200. As a result, a large amount of resin is not charged between the upper surface of the rotor core 110 and the upper mold 200, so that the upper mold 200 and the upper surface can be easily attached and detached.

On the other hand, in the transfer molding method, since the resin is filled in the cavity between the semiconductor chip and the mold, it is necessary to mold the mold well from the molded product. For this reason, the releasability of the mold and the molded article is particularly required for the resin sealing the semiconductor chip.

The rotor 100 of the present embodiment can be mounted on a vehicle such as a hybrid vehicle, a fuel cell vehicle, an electric vehicle such as an electric vehicle, a train, and a ship.

Example

Hereinafter, the present invention will be described in detail with reference to Examples, but the present invention is not limited to the description of these Examples at all. Unless otherwise stated, " parts " and " parts by mass "

The raw material components used in the respective Examples and Comparative Examples are shown below.

(Thermosetting resin (A))

Epoxy resin 1: biphenyl type epoxy (YX4000K manufactured by Mitsubishi Chemical Corporation, ICI viscosity at 150 캜: 0.11 poise)

Epoxy resin 2: tetramethyl bisphenol F type epoxy resin (YSLV-80XY, manufactured by Shin-Nittsu Chemical Co., Ltd., ICI viscosity at 150 캜: 0.03 poise)

Epoxy resin 3: Orthocresol novolak type epoxy resin (EPICLON N-665, manufactured by DIC, ICI viscosity at 150 캜: 3.06 poise)

Epoxy resin 4: Phenol aralkyl type epoxy having phenylene skeleton (NC-2000, ICI viscosity at 150 캜: 1.20 poise)

Epoxy resin 5: phenol aralkyl type epoxy having biphenylene skeleton (NC3000, ICI viscosity at 150 캜: 0.85 poise)

Epoxy resin 6: Triphenyl methane type epoxy resin (E-1032H-60, manufactured by Nippon Yakusho Chemical Co., Ltd., ICI viscosity at 150 캜: 1.30 poise)

Epoxy resin 7: orthocresol novolak type epoxy resin (EPICLON N-670, manufactured by DIC, ICI viscosity at 150 캜: 4.28 poise)

The melt viscosity (ICI viscosity) at 150 캜 was measured with a cone plate type viscometer CV-1S (manufactured by Toa Kogyo Co., Ltd.).

(Curing agent (B))

Phenol resin type curing agent 1: novolak type phenol resin (manufactured by Sumitomo Bakelite, PR-HF-3, ICI viscosity at 150 캜: 1.08 poise)

Phenol resin-based curing agent 2: Phenol aralkyl resin having phenylene skeleton (MEH-7800-4S, manufactured by Meiwa Chemical Industries, Ltd., ICI viscosity at 150 ° C: 0.73 poise)

Phenol resin-based curing agent 3: phenol aralkyl resin having a biphenylene skeleton (MEH-7851SS manufactured by Meiwa Chemical Industries, Ltd., ICI viscosity at 150 캜: 0.68 poise)

Phenol resin-based curing agent 4: phenol resin (manufactured by Air Water, HE910-20, ICI viscosity at 150 캜: 1.5 poise) mainly comprising a reaction product of 2-hydroxybenzaldehyde, formaldehyde and phenol,

Phenol resin type curing agent 5: novolak type phenol resin (PR-51714, manufactured by Sumitomo Bakelite, ICI viscosity at 150 캜: 1.64 poise)

(Inorganic filler (C))

Spherical silica 1 (FB-950, manufactured by Denki Kagaku Kogyo Co., Ltd., average particle diameter D ₅₀ 23 탆)

Spherical silica 2 (FB-35, manufactured by Denki Kagaku Kogyo K.K., average particle size D ₅₀ 10 占 퐉)

Spherical silica 3 (manufactured by Adomatex, SO-25R, average particle diameter D ₅₀ 0.5 μm)

Alumina (DAW-45, manufactured by Denki Kagaku Kogyo Co., Ltd., average particle diameter D ₅₀ 43 m)

(Curing accelerator (D))

Curing accelerator 1: Triphenylphosphine

Curing accelerator 2: A curing accelerator represented by the following formula (7)

(7)

Curing accelerator 3: Curing accelerator represented by the following formula (8)

[Chemical Formula 8]

Curing accelerator 4: A curing accelerator represented by the following formula (9)

[Chemical Formula 9]

Curing accelerator 5: A curing accelerator represented by the following formula (10)

[Chemical formula 10]

(Coupling agent (F))

Coupling agent 1: phenylaminopropyltrimethoxysilane (CF4083 manufactured by Toray Dow Corning Incorporated)

Coupling agent 2:? -Glycidoxypropyltrimethoxysilane (KBM-403, Shin-Etsu Chemical Co., Ltd.)

(Inorganic flame retardant (G))

Aluminum hydroxide (CL-303 manufactured by Sumitomo Chemical Co., Ltd.)

(Other additives)

Ion trapping agent: hydrotalcite (trade name: DHT-4H, manufactured by Kyowa Chemical Industry Co., Ltd.)

Colorant: Carbon black (MA600, manufactured by Mitsubishi Chemical Corporation)

Release agent: montanic acid ester wax (manufactured by Hoechst, Kostwax E)

Low stress 1: Silicone resin (KMP-594, Shin-Etsu Chemical Co., Ltd.)

Low stress 2: Silicone oil (TZ-8120, manufactured by Toray Dow Corning Co., Ltd.)

(Example)

With respect to the examples and comparative examples, the respective components were blended according to the blending amounts shown in Table 1 and Table 2 were mixed at room temperature using a mixer to obtain a powdery intermediate. The obtained powdery intermediate was loaded on an automatic feeding device (hopper), and a predetermined amount was supplied to a heating roll at 80 ° C to 100 ° C to carry out melt kneading. Thereafter, it was cooled and then pulverized to obtain a fixing resin composition. The tablets were obtained by subjecting the fixing resin composition obtained by using the molding apparatus to tablet molding.

On the other hand, a rotor was produced by the following procedure using an insert molding apparatus having a top mold 200 shown in Fig. First, the rotor core was fixed to the lower mold of the molding apparatus, the neodymium magnet was inserted into the hole portion of the rotor core, and the lower mold was elevated to press the upper mold 200 on the upper surface of the rotor core. Subsequently, the fixing resin composition on the tablet was supplied to the port 210 of the upper mold 200. Then, the resin composition for fixation in the molten state was pushed out from the port 210 by a plunger to fill the hole and the interstices of the neodymium magnet with the fixing resin composition. Then, the filled fixing resin composition was heated and cured to form a fixing member to obtain a rotor. The molding conditions at this time were a rotor core temperature of 160 DEG C and a curing time of 120 seconds.

The obtained fixing resin composition and the rotor were subjected to the following measurement and evaluation. The results are shown in Tables 1 and 2. The rotor of the example was excellent in strength.

(Evaluation Items)

Spiral flow: A low-pressure transfer molding machine (KTS-15, manufactured by Kotaku Kogyo Co., Ltd.) was used for insert molding, and a mold for spiral flow measurement according to ANSI / ASTM D 3123-72 was set at 175 캜, MPa, and a pressure holding time of 120 seconds, and the flow length was measured. The spiral flow is a parameter of fluidity, and the larger the value, the better the fluidity. The unit of the spiral flow in Tables 1 and 2 is cm.

Gel time: The resin composition for fixation was placed on a hot plate controlled at 175 캜, and sputtered at about once / sec. Kneading with a stroke of. The time until the fixing resin composition was dissolved by heat and hardened was measured to obtain a gel time. The unit of gel time in Tables 1 and 2 is seconds.

(CFT-500D, manufactured by Shimadzu Seisakusho Co., Ltd.) after making the tablet resin composition (11 mm in diameter and 15 mm in height) of a fixing resin composition having a viscosity of about 2.5 g (Dice) having a diameter of 0.5 mm and a length of 1.0 mm under the conditions of a temperature of 175 ° C and a load of 10 kg. The unit of the modified viscosity in Tables 1 and 2 is Pa · s.

The curing torque of the fixing resin composition was measured at a measurement temperature of 175 占 폚 with the use of a curing raster meter (manufactured by ORI-TECH Corporation, JSR Cure Rastometer IVPS type) The ratio of the curing torque value after 60 seconds from the start of measurement to the maximum curing torque value up to 300 seconds after the start of measurement when T _{60 is the} curing torque value after 60 seconds from the start of measurement and T _max is the maximum curing torque value after 300 seconds from the start of measurement T ₆₀ / T _max (%) was obtained as a cure ratio torque ratio. The torque in the cure raster meter is a parameter of thermal stiffness. For this reason, the larger the cure ratio torque ratio is, the better the curability is.

Slit flow length: A resin composition for fixing was injected into a mold having a groove (slit) having a specific thickness opened at its tip and formed radially under the conditions of a mold temperature of 175 DEG C, a molding pressure of 6.9 MPa, an injection time of 20 seconds, and a curing time of 90 seconds And the length of the resin flowing into the slit having a width of 3 mm and a thickness of 80 m was measured with a nog- ness. Unit is mm.

Rotor formability: A metal piece (width 28 mm, thickness 3.5 mm, length 74 mm) assumed as a magnet was inserted into a mold assumed as an electromagnetic steel plate (hole width 30 mm, thickness 4 mm, depth 75 mm) Was set in a molding machine, and at the time when the mold reached 170 DEG C, the fixing resin composition was injection molded, and after the curing time was 120 seconds, the mold was taken out from the molding machine. The appearance of the molded article was visually inspected to see if there was any abnormality such as voids, and those with no abnormality such as voids were rated & cir &

Glass Transition Temperature: A low-pressure transfer molding machine (KTS-30, manufactured by Kotaku Kogyo Co., Ltd.) was dedicated to insert molding, and the fixing resin composition was injection-molded under the conditions of a mold temperature of 175 캜, an injection pressure of 9.8 MPa, and a curing time of 2 minutes A test piece of 4 mm x 4 mm x 15 mm was obtained. The obtained test piece was post-cured at 175 캜 for 4 hours and then heated at a temperature rising rate of 5 占 폚 to a temperature range of 0 占 폚 to 320 占 폚 using a thermomechanical analyzer (TMA100, manufactured by Seiko Instruments Inc.) The coefficient of linear expansion (? 1) in the region below the glass transition temperature and the coefficient of linear expansion (? 2) in the rubber-like phase region are determined from the chart when measured in ° C / min. At this time, the point of intersection of extension lines of? 1 and? 2 was defined as the glass transition temperature. In Tables 1 and 2, the unit of glass transition temperature is ° C, and the unit of linear expansion coefficient (α1, α2) is ppm / ° C.

Flame resistance: A low-pressure transfer molding machine (KTS-30, manufactured by Kotaku Kogyo Co., Ltd.) was used for insert molding, and the fixing resin composition was injected under conditions of a mold temperature of 175 캜, an injection pressure of 9.8 MPa, an injection time of 15 seconds, and a curing time of 120 seconds Molded to prepare an internal combustion test piece having a thickness of 127 mm x 12.7 mm x 3.2 mm. Using these test pieces, an internal combustion test was carried out in accordance with the UL94 vertical method standard to determine the flame resistance. Internal combustion ranks and so on. In the present invention, since the flame retardancy is not a necessary condition, the flame retardancy may be appropriately adjusted.

Breaking energy a and b: A cured product of a resin composition for rotor fixing (hereinafter referred to as a test piece) molded into a dumbbell shape in accordance with JIS K7162 was subjected to a tensile test at 25 ° C or 150 ° C under a load speed of 1.0 mm / min Respectively. In this tensile test, Tensilon UCT-30T manufactured by Orientec Corporation was used for Tensilon, and Type KFG-2-120-D16-11L1M2R manufactured by Kyowa Engineering &

A curve (stress-strain curve) was created by graphing the relationship between the normal stress and the strain at the time of the tensile test. Next, an integral value of the stress from the starting point of the tensile test to the breaking point was calculated using the strain as a variable. In addition, the unit was set to 10 ^-4 J / min.

Molding resistance: The resin composition for fixation was injection-molded using a molding machine (KTS-30, manufactured by Kotakiri Kogyo Co., Ltd.) at a mold temperature of 175 캜, an injection pressure of 9.8 MPa and a curing time of 120 seconds, (Cured product) having a thickness of 4 mm was obtained. The obtained molded article was post-cured and heated at 175 캜 for 4 hours to obtain test specimens. The flexural strength and the flexural modulus were measured in an atmosphere of 25 캜 according to JIS K 6911. Subsequently, the test piece was placed in a pressure-resistant container and immersed in a pressure-resistant container at a temperature of 150 DEG C for 1000 hours in a state filled with ATF oil (Nissan Matic Fluid D), and then the bending strength and the bending elastic modulus were measured in the same manner as described above . The change rate was 10% or less with respect to the initial value before ATF oil immersion, and the case where the change rate exceeded 10% was rated as x.

ATF immersion test (1000 hours) Using a molding machine (KTS-30, manufactured by Kotaku Kogyo Co., Ltd.), a fixing resin composition was injection molded at a mold temperature of 175 캜, an injection pressure of 9.8 MPa and a curing time of 120 seconds, , A width of 10 mm, and a thickness of 4 mm (cured product). The obtained molded article was heat-treated at 175 캜 for 4 hours as a post-curing test piece, and the weight X1 and volume Y1 before ATF immersion were measured. Subsequently, the test piece was placed in a pressure-resistant container, and immersed in ATF at 150 DEG C for 1000 hours. Then, the test piece was taken out from the pressure-resistant container and the ATF adhering to the surface was wiped off. Then, the weight X2 and the volume Y2 after ATF immersion were measured, and the weight change rate and the volume change rate before and after ATF immersion were respectively calculated from the following equation.

Weight change rate before and after ATF immersion [%] = (X2-X1) / X1 100

Volume change rate before and after ATF immersion [%] = (Y2-Y1) / Y1 100

As the ATF, Mat Fluid D (AUTO FLUID TYPE T-IV (manufactured by Toyota Motor Corporation) and ATF DW-1 (manufactured by Honda Kiken Kogyo Co., Ltd.) manufactured by Nissan Motors were used.

ATF immersion test (2000 hours): Weight change rate and volume change rate before and after immersion in ATF were calculated in the same manner as in ATF immersion test (1000 hours), except that the immersion time for ATF was changed to 2000 hours.

Removal of inorganic filler: After the ATF immersion test, the ATF oil was filtered and the presence of inorganic filler on the filter paper was confirmed by a microscope.

From Examples 1 to 6, it was found that a fixing resin composition having excellent charging characteristics, mechanical properties and oil resistance, and capable of exhibiting good properties even in the ATF immersion test was obtained.

In Comparative Examples 1 and 2 in which the epoxy resin had an ICI viscosity of more than 3, all 80 μm slit flow lengths were less than 75. As described above, in Comparative Examples 1 and 2, a fixing resin composition having sufficient filling properties could not be obtained.

Needless to say, the above-described embodiment and the plurality of modifications can be combined within a range not inconsistent with the contents. While the structure and the like of each part have been specifically described in the above-described embodiments and modifications, the structure and the like can be variously modified within the scope of satisfying the present invention.

100 rotor
110 rotor core
112 steel plate
114 end plate
116 groove
118a, 118b end plate
120 magnets
121 side wall
123 side wall
130 fixing member
140 live part
150 hole
151 side wall
152 hole
153 side wall
154a, 154b,
156 hole
160 caulking portion
170 shaft
200 HYPER
210 port
220 Euro

Claims (17)

A rotor core having a laminated body in which a plurality of plate members are laminated and fixed to the rotating shaft and having a plurality of holes formed in the laminated body along the periphery of the rotating shaft;
A magnet inserted into the hole,
And a fixation member which is formed by curing the fixing resin composition filled in the hole portion and the gap portion of the magnet,
A resin composition for fixing used for the fixing member constituting the rotor,
An epoxy resin (A) having an ICI viscosity of 3 poise or less at 150 DEG C of 5% by mass or more and 40% by mass or less,
A curing agent (B) having an ICI viscosity of 2 poise or less at 150 DEG C of 3% by mass or more and 35% by mass or less,
And 50% by mass or more and 91% by mass or less of the inorganic filler (C)
The slit flow length when injecting the fixing resin composition into a flow path having a cross-sectional shape of 3 mm in width and 80 탆 in thickness at a mold temperature of 175 캜, a molding pressure of 6.9 MPa and an injection time of 20 seconds was 75 mm to 300 mm By weight or less. The method according to claim 1,
Wherein the epoxy resin is selected from the group consisting of biphenyl type epoxy resin, phenol aralkyl type epoxy resin having phenylene skeleton, phenol aralkyl type epoxy resin having biphenylene skeleton, phenol novolak type epoxy resin, At least one member selected from the group consisting of a bisphenol type epoxy resin, a bisnaphthol type epoxy resin, a dicyclopentadiene type epoxy resin, a dihydroanthracene diol type epoxy resin and a triphenylmethane type epoxy resin. The method according to claim 1,
Wherein the curing agent (B) is selected from the group consisting of novolac phenol resins, phenol aralkyl resins having phenylene skeleton, phenol aralkyl resins having biphenylene skeleton, naphthol aralkyl resins having phenylene skeleton, hydroxybenzaldehyde and formaldehyde A phenol resin containing a reaction product of phenol, and a copolymer of a triphenylmethane type phenol compound and a novolak type phenol compound. The method according to claim 1,
Wherein the epoxy resin is a crystalline epoxy resin. The method according to claim 1,
Wherein the fixative resin composition has an adjusted viscosity of 3 Pa · s or more and 50 Pa · s or less when measured at 175 ° C. and a load of 10 kg using an apparatus for measuring high viscosity. The method according to claim 1,
Wherein the fixing resin composition has a gel time at 175 캜 of 10 seconds or more and 50 seconds or less. The method according to claim 1,
Wherein the fixing resin composition has a spiral flow of 50 cm or more. The method according to claim 1,
Cure Las maximum cure torque at the measured temperature 175 ℃ using Sat meters to the values fixed resin after 60 seconds cure torque start of measurement when the composition measurement of the curing torque with time for T _60, measurement start after 300 seconds T _max values when in, the non-T ₆₀ / T _max (%) is 40% or more fixed-resin composition for use in the measurement start value after curing torque 60 seconds for a maximum cure torque value up to 300 seconds after start of the measurement. The method according to claim 1,
Powder, granule or tablet. The method according to claim 1,
Wherein the distance between the hole portion and the separated portion of the magnet in the radial direction of the rotor is 20 占 퐉 or more and 500 占 퐉 or less when viewed from the top surface. A rotor core having a laminated body in which a plurality of plate members are laminated and fixed to the rotating shaft and having a plurality of holes formed in the laminated body along the periphery of the rotating shaft;
A magnet inserted into the hole,
And a fixation member which is formed by curing the fixing resin composition filled in the hole portion and the gap portion of the magnet,
And a rotor
The rotor according to any one of claims 1 to 10, wherein the fixing resin composition for use in the fixing member constituting the rotor is the fixing resin composition according to any one of claims 1 to 10. A motor vehicle having the rotor according to claim 11. A process for producing a rotor using the fixing resin composition according to any one of claims 1 to 10,
A step of preparing a rotor core having a laminate in which a plurality of plate members are laminated and in which a plurality of holes arranged in a peripheral portion of a through hole through which the rotating shaft penetrates are formed in the laminate;
A step of inserting a magnet into the hole,
A step of filling the hole portion and the spacer portion of the magnet with the fixing resin composition,
And inserting the rotating shaft into the through-hole of the rotor core, and fixing the rotating shaft to the rotor core. delete delete delete delete

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